Method and apparatus for making space-dyed yarns

ABSTRACT

Space-dyed yarn rovings or rovings having successive portions of relatively different dye affinity are produced for the subsequent spinning of yarns therefrom by forming a sliver or a lap of slivers having successive portions of relatively different color and/or dye affinity characteristics, and feeding the sliver or lap into a finisher carding machine with the portions thereof of relatively different characteristics entering the carding machine in succession so as to form a carded web of corresponding successive portions. The carded web is then split into a plurality of strips which are converted into yarn rovings while preserving the different characteristics of the successive portions thereof.

United. States Patent [1 1 Moore et al.

[ METHOD AND APPARATUS FOR MAKING SPACE-,DYED YARNS I I [75] Inventors: James Melvin Moore, Greenville;

William Gilbert Newell, Asheville; Anthony Everette Hampton, Asheville; Philip Elmo Jackson, Asheville, all of NC.

[73] Assignee: Fieldcrest Mills, Inc., Eden, NC.

[22] Filed: Oct. 20, 1971 [2 1] Appl. No.: 191,004

521 user ..19/ 163 ,19/145.7

[51] Int. Cl D04h 11/04 [58] Field of Search l9/l45.7, I63, 145, 145.5, 19/105, 160, 161 R, 106 R, 157

[56] References Cited UNITED STATES PATENTS 1,572,148 2/1926 Kerwin, Jr. 19/l45.7 l,637,l39 7/l927 Clow ct al l9/l45.7 UX 2.927.350 3/1960 Nelson l9/l63 1 3,815,179 June 11,1974

FOREIGN PATENTS OR APPLICATIONS 253,685 ll/l9l2 Germany [9/145 Primary Examiner-Dorsey Newton Attorney, Agent, or FirmParrott, Bell, Seltzer, Park & Gibson into yarn rovings while preserving the different characteristics of the successive portions thereof.

5 Claims, 12 Drawing Figures PATENTEDJUHH m4 3315179 SHEET 30$ 6 Pmmzmun 11 m 3315; 179

SHEET t 0F 6 Am, SUPPLY SPACE-DYED YARNS In the preparation of pile yarns for use in making variegated carpet fabrics, it is common practice to spacedye or random-dye such yarns, usually by spinning the yarns, forming skeins therefrom and manually dipping successive spaced portions of the yarn skeins in a container of liquid dye. The skeins then may be transferred to another container having a different colored dye liquid therein into which the intervening portions of the yarn skeins are dipped. In most instances, the yarns on the skeins are predyed throughout their length before being overdyed at spaced portions thereof by the manual dipping process. Although recent developments in the art have partially automated the dipping procedure in space-dyeing operations, it is, nevertheless, an expensive, laborious and time consuming procedure.

Therefore, it is an object of this invention to provide 'an improved apparatus and method for producing space-dyed carpet pile yarns at substantially reduced cost by eliminating the aforementioned dipping procedure, and wherein the dyeing of the yarns. may be effected either by predyeing the fibers of which the various sections of each yarn are subsequently formed or by forming the various sections of each yarn from fibers of correspondingly variant dye affinity 80 that the space-dyed effect may be imparted to. the yarns in subsequent piece-dyeing of the woven, knitted or tufted carpet formed therefrom.

It is another object of this invention to provide apparatus and methods for producing space-dyed yarns wherein a lap is formed by arranging successive lengths of textile sliver widthwise of and behind a finisher carding machine with each of the lengths corresponding substantially to the width of the carding machineand with some of the lengths being of a different characteristic, such as color or dye affinity, than others of the lengths. The thus arranged lengths are. fed into the carding machine in succession to form therefrom a carded web having successive portions of relatively different characteristics corresponding to the. different characteristics of the successive lengths ofthe slivers fed into the carding machine, while-the carded. webis split into a plurality of strips and converted into yarn rovings ready for spinning yarns therefrom.

According to the invention, the slivers may be formed and prepared for feedingthe same into a finisher carding machine in various ways. in. one embodiment, elongate rows of masses of textile fibers are formed which have longitudinally arranged-fibrous sections each of a different color and/or dye affinity characteristic than the immediately adjacent section thereof. The thus formed rows are fed; in. a. first direction transversely thereof while being accumulated: in

side by side relationship in back ofa breaker carding machine. Upon a predetermined number of such rows being accumulated, they are shifted unitarily'inazdirection at a substantially right angle relative to the first direction and toward the feed'end of'the-breakencarding machine to feed the sections successively into the card'- ing machine and form a carded web having: successive portions of different characteristics corresponding to the different characteristics of the respective sections of the rows of fibers fed into thebreakencardingmachine. The carded webv emerging; from the breaker carding machine is condensedintoa sliver? and cross- 2 laid onto the fed apron of a finisher carding machine to form a lap therefrom which is fed into the finisher carding machine to again form the lap into a carded web which is split into a plurality of strips and formed into yarn rovings.

In a second embodiment of the invention a series of feeders is arranged rearwardly of a breaker carding machine for depositing successive elongate rows of masses of fibers on the feed apron of the breaker carding machine, wherein each row may be of a different characteristic than the immediately succeeding row, so as to form a carded web having successive portions of relatively different characteristics corresponding to the different characteristics of respective successive rows of fibers being fed, whereupon the carded web delivered from the breaker carding machine is condensed into a sliver and cross-laid onto the feed apron of a finisher carding machine as in the first embodiment of the invention. t

In a third embodiment of the invention, side by side .masses of fibers having relatively different colorcharacteristics and/or dye affinity characteristics are fed into abreaker. carding machine to produce individual carded webs having relatively different characteristics. The individual carded webs are condensed into respective slivers and then brought together to form a group of juxtaposed slivers therefrom which are then fed onto the feed apron of a finisher carding machine in the aforementioned manner.

In a fourth embodiment of the invention, slivers having said different characteristics are delivered to a finisher carding machine from respective different breaker carding machines. In a fifth embodiment, individual slivers of relatively different characteristics are taken from respective individual sources, such as sliver cans, and are delivered selectively to the feed apron of the finisher carding machine.

Some of the objects of the invention having been stated, other objects will appear as the description proceeds when taken in connection with the accompanying drawings, in which FIG. 1 is a side elevation of a first embodiment of apparatus for carrying outthe method of this invention, wherein the fiber masses from a fiber feeder are processed successively through a breaker carding machine, a finisher carding machine and a tape condenser, and showing novel transfer means for transferring the masses delivered by the feeder in a-right-angular path onto the feed apron of thebreaker carding machine;

FIG. 2 is a top plan view of the apparatus shown in FIG. 1;

FIG, 3 is an enlarged schematic perspective view looking in the direction of the arrow indicated at 3 in FIG. 2, and showing details of the transfer means and the feeder;

FIG. 4 is a view similar to FIG. 1, but showing a second embodiment of the apparatus in which successive rows of masses of fibers are delivered from a series of feeders onto the feed apron of the breaker carding machine;

FIG. 5 is a schematic plan view of a third embodiment of apparatus for carrying out the. method of this invention wherein a plurality of carded webs of different characteristics are delivered from a single breaker carding machine, combined into a group of juxtaposed slivers, and then fed to a finisher carding machine;

' invention wherein individual slivers of relatively different characteristics are taken from respective independent sources; e.g., sliver cans, and laid on the feed apron of a finisher carding machine;

FIG. 11 is a somewhat schematic rear end elevation of the feed apron of the finisher carding machine taken substantially along line 1 l1l in FIG. and showing novel pattern controlled means for selectively depositing predetermined lengths of sliver from respective packages on the feed apron of the finisher carding machine; and

FIG. 12 is an enlarged fragmentary detail of the mechanism shown in the right-hand medial portion of FIG. 11 for withdrawing successivelengths of sliver from a corresponding sliver can.

FIRST EMBODIMENT Referring more specifically to the drawings, FIGS. 1

and 2 illustrate a novel arrangement of textile machinery particularly devised for carrying out the method of the first embodiment of the invention and wherein a fiber feeder unit 20, an accumulator conveyor means or apron 21, and a fiber transfer means 22 cooperate in a novel manner to form and feed side by side, elongate sectionalized rows of masses of textile fiber into a breaker carding machine 23 of usual type. Aswill be explained more in detail herein, each of the rows of fibers is characterized by having respective longitudinal fibrous sections each of a different characteristic; i.e., color and/or dye affinity, than the immediately adjacent section thereof.

The breaker carding machine 23 forms the rows of fibers into a carded web having successive portions of different characteristics corresponding to the respective sections of the rows of fibers being fed into the breaker carding machine. Such carded web is condensed into a sliver in the usual manner and a cross feeding mechanism 24, commonly known as a scotch feeder, transfers the sliver from the breaker carding machine 23 and cross-lays the sliver onto the usual feed apron of a finisher carding machine 25.

The lap thus formed is again formed into a carded web which is delivered from the finisher carding machine 25 to a tape condenser 26. As is usual, tape condenser 26 splits the web from the finisher carding machine into a plurality of relatively narrow strips which are rolled and rubbed between cooperating belts or tapes to convert the stripsinto yarn rovings. The yarn rovings are taken up on jack spools, 27. From the condenser 26, the rovings are transferred, on jack spools 27, to conventional spinning machines, not shown, to be spun into yarn.

With the important exception of the arrangement of fiber feeder unit 20, accumulator apron 21, and transfer means 22, the several units of machinery heretofore described may be of conventional or other suitable construction and,-therefore, a detailed illustration and description thereof is deemed unnecessary. Although 4 not limited thereto, the method is particularly concerned with the production of carpet yarns made from wool and/or synthetic fibers and it' is preferred there- I forethat the carding machines'are of the full roller type constructed for operation according to the woolen system.

FIBER FEEDER UNIT According to this embodiment, fiber feeder unit 20 forms sectionalized elongate rows of masses 30 of textile fibers which rows have longitudinal sections of relatively different color characteristics and/0r dye affinity characteristics and are fed transversely, in a first direction, onto the accumulator apron 21. Upon accumulation of a predetermined number of such elongate rows 30 on apron 21, the transfer means 22 shifts the accumulated rows of textile fibers unitarily in a second direction, at substantially a right angle to the first direction, onto the feed conveyor. means or apron 23a of breakercardingmachine 23.

In most respects, fiber feeder unit 20 may be of conventional construction, of the general type disclosed in US. Pat. No. 2,702,177, issued to Albert R. Jee'et al. on Feb. 15, 1955, for example, the disclosure of which is incorporated herein by reference. Generally, as shown in FIG. 3, feeder unit 20 comprises a hopper whose bottom and front walls are defined by a substantially horizontal endless hopper feeder conveyor 20a and an inclined endless hopper elevator conveyor 20b driven by an electric motor 200. Feeder unit 20 has been modified by dividing the hopper thereof into a plurality of compartments, there being three such compartments shown at C-1, C-2, O3 in FIG. 3 defined by the outer side walls of the hopper and by suitable spaced partitions 20d which preferably are adjustable to vary the effective widths of the compartments.

Assuming that the fibers deposited in each individual compartment C-l, C-2, C-3 are of a different color and/or dye affinity than the fibers in the other compartments, the elevator conveyor 20b lifts and then deposits the three types of fibers in a balance scale catch pan 20c whose normally 'closed bottom closure means 20f opens automatically and momentarily as is conventional, each time a predetermined weight of stock is deposited thereon so as to deposit a sectionalized elongate row of 'fibers 30 (FIG. 2) on the discharge conveyor means 20g of fiber feeder unit 20. The feeder unit 20 may operate in a conventional manner to temporarily stop elevator conveyor 20b each time the catch pan closure means 20f .is momentarily opened in response to receiving thereon a predetermined weight of stock.

In this instance, since the feeder hopper is divided into three compartments 01, C-2, C-3, each elongate row of fibers 30 includes three aligned sections 30a, 30b, 30c (FIG. 2) which may be of equal or relatively different lengths, according to the adjusted positions of partitions 20d. It is to be noted that feeder unit 20 is positioned rearwardly of and is offset to one side of the feed apron 23a of breaker carding machine 23, and that discharge conveyor means 20g feeds the successively formed rows of fibers 30 in a first direction which is not only transverse of the rows of fibers 30, but which direction extends at substantially a right angle to the direction ofmovement of the card feed apron 23a.

For producing space-dyed yarns for use in making pile fabrics therefrom, the fibers in all the sections of each row 30 may be of the same or different chemical structure; such as wool, cotton, or synthetic fibers or blends thereof, in which case the fibers in each section also may difi'er in color from the fibers in the other sections of the same row. For example, it may be assumed that sections 30a, 30b, 300 of each row of fibers 30 are formed from fibers which were predyed green, yellow and brown, respectively, before they were deposited in the respective hopper compartments C-1, C-2, C-3. For producing yarns to which a space-dyed effect is to be imparted by piece-dying the fabric after it has been formed, fibers having different affinity for a particular dye may be used in the respective compartments C-1, C-2, C-3. Also, one or more of the compartments may contain predyed fibers which would become overdyed during a subsequent piece-dying operation, while another of the compartments may contain undyed fibers. In any event, in order for successive portions of the carded web being formed on the breaker card 23 to be of relatively different characteristics with any given portion thereof being of the same characteristic throughout the width of the carded web, all of the successive sections 30a which accumulate on accumulator conveyor means 21 prior to each operation of transfer means 22, should be of the same length and of the same characteristic as to color or dye affinity. This also applies to the respective sections 30b, 300 of the successively fed masses 30, so as to form respective bands of the same characteristic crosswise of the feed apron 23a, with adjacent bands being of different characteristics relative to each other.

The feeder unit is provided with a reciprocating pusher member or plate 20h which extends over and across discharge conveyor means 20g and functions in a conventional manner to push each successive row of fibers 30 dumped onto discharge conveyor 20g to the nip between the egress end of discharge conveyor and an idler pressure roll 20i resting thereon. The upper run of accumulator apron 21 is preferably on about the same level as feeder unit discharge conveyor means 20g and feed apron 23a and receives each successive row of fibers 30 thereon from discharge conveyor 20g.

Discharge conveyor means 20g, pusher plate 20h and accumulator apron 21 may be driven continuously during operation of breaker carding machine 23 by suitable drive transmission means 32 connecting discharge conveyor means 20g and pusher plate 20h to the front roll 23b of feed apron 23a and to the licker-in feed rolls 23c of breaker carding machine 23.

The speed of discharge conveyor means 20g and accumulator apron 21 is sufficiently greater than that of card feed apron 230 so as to provide time for the accumulation of the desired predetermined number of rows of fibers 30 on accumulator apron 21 and for the transfer thereof onto feed apron 23a by transfer means 22, before the trailing ends of the immediately preceding group of rows 30 have reached the feed rolls 23c of the breaker carding machine. The number of such rows accumulated during each accumulating cycle is dependent upon the desired width and weight per unit length of the sliver being produced by the breaker carding machine and the weight of each row of fibers 30 formed by feeder unit 20.

FIBER TRANSFER MEANS of a rake means including a transfer platform or table 6 22a having a plurality ofclosely spaced teeth or spikes 2212 depending from the major portion of the lower surface thereof. Normally, during accumulation of the desired number of rows of fibers 30 on accumulator conveyor means or apron 21, the spikes 20b of transfer platform 22a are spaced above and overlie proximal portions of aprons 21, 23a. Spikes 22b then are spacedsufficiently above aprons 21, 23a so that they will not obstruct movement of the fibers then being conveyed upon aprons 21, 23a.

Transfer platform 22a is supported and controlled so as to move in a generally rectilinear path substantially parallel with card feed apron 23a during each transfer operation. In so doing, platform 22b is moved rearwardly and then downwardly so that spikes 22b drop into the rows of fibers 30 then on accumulator apron 21. Platform 22b then is moved forwardly at av much faster speed than that of card feed apron 23a to advance all of the rows of fibers 30 from accumulator apron 21 onto card feed apron 23a and against the trailing ends of the preceding rows of fibers 30 forming the lap now being fed to the lickerin 23d of the breaker carding machine 23 by feed rolls 23c. Platform 22a then is moved upwardly to withdraw spikes 22b from the transferred rows of fibers 30 and, thereupon, platform 22b is moved rearwardly to return the same to its normal position of rest shown in FIGS. 1, 2 and 3,

thereby completing a cycle in the operation of transfer means 22.

As shown in FIG. 3, a medial portion of transfer platform.22a is pivotally suspended from a pair of endless sprocket chains 22c, 22d by means of a transverse shaft 222 whose opposite ends are secured to corresponding links of chains 22c, 22d. A pair of bearing blocks 22f are loosely penetrated by shaft 22e, and the bearing blocks 22f are suitably secured to platform 22a. Each of the chains 22c, 22d is mounted on a respective group of sprocket wheels including a front sprocket wheel 22g, an intermediate sprocket wheel 22b and a rear sprocket wheel 22:. Each group of sprocket wheels is joumaled on a stationary elongate frame member 22j which may be fastened to suitable standards, not shown, supported on the floor upon which the carding machines rest.

A sprocket wheel 22k is fixed in axial relation to each sprocket wheel 22g and has'an endless sprocket chain 22m thereon whose lower portion is mounted on a sprocket wheel 22n. Both sprocket wheels 22n are fixed on a common shaft 22p extending beneath card feed apron 23a, thus abviating the need for any shaft extending between frame members 22j and thereby to avoid obstructing the path of travel of transfer platform 22a. Shaft 22;) is driven at predetermined intervals by suitable connections with an electric drive motor 221;.

Transfer 22a is pivotally suspended so that its supporting shaft 22e may pass about the axes of sprocket wheels 22g and 221' while platform 22a remains in a substantially horizontal or slightly angular position. Therefore, in order to prevent excessive tilting of platform 22a about shaft 22e as shaft 22e moves about the axes of the sprocket wheels 22g, 221 at the ends of the respective forward and rearward strokes of platform 22a, the forward and rearward portions of platform 22a, adjacent opposite sides thereof, are provided with upwardly projecting guide elements or rollers 22r, 22s which are adapted to ride against the lower surfaces of 7 elongate guide tracks. 22: overlying opposing side portions of transfer platform 22a and being carried by the respective elongate frame members 22j.

Although the rear end portion of transfer platform 22a may tilt downwardly as shaft 22e moves about the axis of sprocket wheels 221', upon the rearmost spikes 22b contacting accumulator apron 21, the guide rollers 22s will move away from tracks 22r as platform 22a starts to return to its normal substantially level position. Thus platform 22a will occupy a substantially level position, parallel to the upper surfaces of aprons 21, 23a,

roll 20i'and'thus is advanced in a first direction transversely thereof onto accumulator apron 21.

throughout subsequent forward movement thereof in transferring accumulated rows of fibers 30 from accumulator apron 21 onto card feed apron 230. Similarly, as shaft 22e moves upwardly about the axis of front sprocket wheels 223, the front portion of transfer platform 22a will move upwardly at an angle ahead of the rear portion thereof, whereupon front rollers 22r will engage the tracks 22: so that the platform 22a will return to substantially level position at about the time that shaft 22s reaches the level of the upper reaches of sprockets chains 22c, 22d.

TIMING DEVICE The transfer means 22, hopper feeder conveyor a and hopper elevator conveyor 20b are controlled by a suitable timing device 35 including a rotary cam 35a which may be driven by suitable transmission means generally designated at 35b. Transmission means 35b connects one of the rolls of hopper discharge conveyor means 20g to cam 35a so that cam 350 will rotate one revolution for each composite cycle of fiber feeder unit 20 and transfer means 22. A composite cycle embraces that period of time required for hopper discharge conveyor means 20g to discharge the desired predetermined number of rows'of fibers 30 onto accummulator apron 21 and the time required for a corresponding cycle in the operation of transfer means 22.

Cam 35a engages and opens a normally closed feeder control switch 356 interposed in an electrical circuit to motor 200 to drive hopper conveyors 20a, 20b during intervals in which rows 'of fibers 30 are not to be formed. An offset projection 35d on cam 35a also momentarily closes a normally open transfer control switch 35e arranged in parallel with switch 350 and which initiates each operation of motor 22: through a suitable holding relay 35f. Relay 35fthen establishes a holding circuit for motor 22q through a normally closed stop switch 35g carried by one of the tracks 22:. As transfer platform 22a approaches the end'of a cycle thereof, an actuator 35h on chain 22c engages and momentarily opens stop switch 35g to interrupt operation of relay 35f. Motor 22:; then coasts sufficiently to move actuator 35g out of engagement with stop switch 35g.

In operation of the first embodiment of the invention, it may be assumed that a group of six rows of fibers 30, for example, and each having three fibrous. sections 30a, 30b, 30a of different characteristics (FIG. 2), is to be fed to breaker carding machine 23 during each composite cycle of feeder unit 20 and transfer means 22. Accordingly, with the low surface of cam 35a aligned with switch 35c (FIG. 3), hopper conveyors 20a, 20b are thus feeding fibers into catch pan 20c. Successive elongate rows of fibers 30 are thus deposited on hopper discharge conveyor means 20g, and each successive row 30 is pushed, by pusher plate 20h, toward pressure Since the successive rows of fibers are substantially the same with respect to the color and/or dye affinity characteristics of the respective sections thereof, it is apparent that as a substantial number of rows 30 accumulates on apron 21 they collectively form a series of elongate bands extending widthwise of and behind the carding machine 23. The number of rows 30 and the width thereof should be such that each of the widthwise bands will be of a length corresponding substantially to the width of the carding machine. Also, it is apparent that at least some of the bands thus formed will differ from each other as to the aforementioned characteristics.

Upon accumulation of a group of about six side by side rows of fibers 30 on accumulator apron 21, the high surface of cam a engages and opens normally closed switch 350 to stop motor 200 and hopper conveyors 20a, 20b. However, since hopper discharge conveyor means 20'g and accumulator apron 21 are driven continuously, they continue to advance the group of rows 30, but before the thus formed lap'reaches the desired optimum position in alignment with feed apron 23a'of breaker carding machine 23, the offset projection 35eon cam 35a engages and momentarily closes switch 352 to start operation of motor 22q and thus initiate a cycle in the operation-of transfer means 22.

Thus, transfer platform 22a moves rearwardly from its normal position of rest and, at about the time that the spikes 22b start to enter the rows of fibers 30 then on accumulator apron 21, the center of the group of rows is substantially aligned with the longitudinal center of breaker carding'machine 23. Thereupon, transfer platform 22a moves forwardly, from right to left in FIG. 3 and from left to right in FIGS. 1 and 2, to transfer the previously formed lap onto feed apron 23a with the leading portion of the corresponding lap spaced a predetermined distance rearwardly from the feed rolls 23c and so that the leading end of the corresponding lap will be positioned in close proximity to or against the trailing end of the immediately preceding lap being fed to the breaker carding machine.

Transfer platform 22a and its spikes22b then move upwardly and rearwardly in the manner heretofore described to withdraw the spikes 22b from the lap now positioned on card feed apron 22a and to return the transfer platform 22a to the position of rest shown'in FIG. 3. At a predetermined instant during operation of transfer means 22, the high surface of cam 35a moves out of engagement with switch 35c. This permits switch 350 to close and thereby cause motor 200 to again drive hopper conveyors 20a, 20b to initiate another cycle in the operation of the feeder unit 20. The actuator 35h on chain 22c then moves into engagement with and momentarily opens stop switch 353 todeenergize motor 22q through relay 35f, whereupon actuator 35h returns to substantially the position shown in FIG. 3.

It should be noted that the delay period which transpires between the time that motor 200 is deenergized and motor 221 is energized during each composite cycle need only be sufficient to insure that each successive group of rows of fibers 30 delivered to accumulator conveyor 21 may be spaced from each preceding group sufficiently so that transfer platform 22a will not tend to advance the leading row 30 of a succeeding group then being formed and advanced in said first direction at the same time that the transfer platform 22a is advancing a previously completely formed group in a second direction at substantially aright angle to the first direction and toward the card feed rolls 23c.

The operation of the breaker carding machine 23, scotch feeder 24, finisher carding machine 25, tape condenser 26 and jack spools 27 (FIGS. 1 and 2) proceeds in the manner heretofore described during repeated composite cycles of fiber feeder unit and transfer means 22 to produce rovings each having elongate sections of relatively different color characteristics and/or dye affinity characteristics. In other words, if the fibers in the respective sections 30a, 30b, 30c were pre-dyed green, yellow, and brown respectively, as stated earlier herein, it is apparent that the rovings and yarns spun therefrom would include repeated patterns of series of green, yellow, and brown sections therein.

The conventional scotch feeder 24 may be of a well known type such as is disclosed in US. Pat. No. 1,610,209, dated Dec. 7,1926, for example. As is well known, such a conventional scotch feeder forms a loop or fold in the sliver being cross-laid onto the feed apron of a finisher carding machine at each end of the traverse of the scotch feeder. Thus, in the present embodiment, the carded web being formed by the finisher carding machine 25, and the rovings being formed therefrom, include blends of fibers of two different characteristics at the junctures of adjacent sections of the rovings, which effect also is present in the yarn subsequently formed from the rovings on a spinning machine. Generally, the blending of fibers of different color and/or dye affinity characteristics at the juncture of adjacent sections of the rovings or yarns formed therefrom is not objectionable and may even be desirable in most carpet yarns, especially when the successive sections of the yarns are each of substantial length, as is the case when the arrangement of the different characteristics of fibers is established in series before the fibers enter the breaker carding machine, and as is thecase in this embodiment and the second embodiment to be presently described.

SECOND EMBODIMENT ranged in series, as in the first embodiment shown in FIGS. 1, 2, and 3. However, instead of utilizing a single fiber feeder unit as in FIGS. 1, 2 and 3, the second embodiment utilizes a plurality of fiber feeder units 50, 51,

52 for feeding respective masses of fibers onto the feed apron 43a of breaker carding machine 43. In this instance, the fibers in the hopper of each feeder unit -52 should be of a different color and/or dye affinity characteristic from the fibers in the hoppers of the other feeder units. Also, all of the fibers in any one of the hoppers preferably are of the same color and/or dye receptivity.

As shown in FIG. 4, fiber feeder units 50,-51, 52 are positioned in a row rearwardly of carding machine 43, but with their elongate catch pans 50a, 51a, 52a arranged in series overlying and extending across the rear portion of the breaking card feed apron 43a. Fiber feeder units 50, 5.1, 52 may be driven in timed relation to feed apron 43a by suitable drive transmission means, not shown, but which-may be similar to that indicated at 32 inFIG. 3. The rear and intermediate fiber feeder units 50, 51, in FIG. 4 are provided with respective ducts 50b, 51b which extend over front feeder unit 52 and have respective driven aprons 500, 51c therein for delivering the fibers from the hoppers of feeder units 50, 51 to their respective catch pans 50a, 50b. In other respects, all three fiber feeder units 50, 51, 52 may be conventional and may be similar to feeder unit 20 of FIG. 3, with the exception that the divider partitions 20d may be omitted. Therefore, a more detailed description of fiber'feeder'units 50-52 is deemed unnecessary.

It is apparent that the catch pans 50a, 50b, 50c serve as depositing means for feeding and repeatedly depositing respective like amounts of masses of fibers on conveyor or apron 430 while arranging the fibers into a series of elongate rows or bands 55 extending widthwise of and behindthe carding machine 43. Of course, since the catch pans are of a'length about equal to the width of apron 43a, each row or band of fibers thus deposited is of a length corresponding substantially to the width of carding machine 43. Also, some of the bands thus formed differ from each other as to the aforementioned characteristics. a

A pusher member or plate 54 is provided for advancing forwardly the rows of massesof fibers 55 deposited on feed apron 43a by catch pans 50a, 51a, 52a toensure that the successive rows 55 are juxtapositioned in close proximity to each other or in touching engagement as they enter the licker-in section of the breaker carding machine 43 and so that the carded web being formed thereon will be of substantially uniform weight per unit'length. Pusher plate 54 may be operated by a fluid-operated ram or rams 54a suitably controlled so as to occupy the inactive position shown in solid lines in FIG. 4, rearwardly of the vertical planes of catch pans 50a, 51a, 52a, whilefibrous masses are being dumped. from the catch pans and deposited upon the breaker card feed apron 43a, and so that the pusher plate 54 will move forwardly to substantially the broken line position shown in FIG. 4 and then return to the solid line position before a succeeding fibrous mass is discharged from any one or more of the catch pans 50a, 51a, 52a. The fluid-operated ram or rams 54a may be controlled by any suitable timing means such as the timing device 35 shown in FIG. 3 and, therefore, an illustration and description of the means forcontrolling the fluid-operated ram or rams 54a is deemed unnecessary. A similar timing device may also be provided forcontrolling the operation of each of the fiber feeder units 50, 51, 52 so that fibrous masses may be discharged from the catch pans 50a, 51a, 52a selectively; i.e., one at a time, two at a time, or from all of the catch pans, according to the desired pattern of colors to be present in the rovings and resultant yarns being produced. In other respects, the carding machines 43, 45, scotch feeder 44 and condenser 46 operate in the same manner as the carding machines 23, 25, scotch feeder 24 and condenser 26 of the first embodiment of the invention,'and therefore, a further description thereof is deemed unnecessary.

THIRD EMBODIMENT The third embodiment of the invention is shown in FIG. 5 and includes a fiber feeder unit 60, a breaker I 1 1 carding machine 63, a cross-feeding mechanism or scotch feeder 64, a finisher carding machine 65, a condenser 66 and jack spools 67 arranged in series. The fiber feeder unit 60 may be identical to the fiber feeder unit 20 of FIG. 3 but may be driven continuously during the operation of breaker carding machine 63. Also, fiber feeder unit 60 is positioned rearwardly of and in alignment with the feed apron 63a of breaker carding machine 63 so that the fibers discharged therefrom extend across substantially the entire width of breaker card apron 63a. However, each time the fiber feeder unit 60 discharges fibers onto breaker card feed conveyor 63a, the fibers are divided into a plurality of separate masses of relatively different color characteristics and/or dye affinity characteristics byvirtue of the fact that the hopper portion of fiber feeder unit 60 is provided with spaced partitions or divider walls 60a which divide said hopper portion into a plurality of side by I side compartments, there being three such compartments shown in FIG. 5 indicated at 60b, 60c, 60d. Preferably, each of the compartments 60b, 60c, 60d is provided with a supply of textile fibers of a color and/or dye affinity which is different from that of the fibers in the other compartments.

Also, in order to maintain the fibers' of different color and/or dye affinity characteristics segregated from each other throughout their passage through the breaker carding machine 63, suitable segregating means 63b is aligned substantially with the partitions 50a and extends substantially throughout the length of the carding machine; i.e., the segregating means 63b extends from the discharge conveyor of the fiber feeder unit 60 along the breaker card feed conveyor 63a and about the usual licker'in, fiber transfer cylinders and main cylinders of thebreaker carding machine. Those portions of the segregating means 63b above the discharge conveyor or fiber feeder unit 60 and above the breaker card feed apron 63a may be in the form of suitable partitions, and those portions of the segregating means 63b extending about the licker-in, the transfer cylinders and the main cylinders of the breaker carding machine 63 may be in the form of suitable shield strips shielding the card clothing thereon from the fibers being directed thereto from the feeder apron 63a. The shield strips may be in the form of pliable tapes or any other suitable material which will form a shielded band of about 1 to 2 inches in widthentirely around each of the transfer cylinders, main cylinders and the licker-in of the breaker carding machine 63. i

Thus, three separate carded webs, each of a different color characteristic and/or dye affinity characteristic than that of the others, are formed on the breaker carding machine 63. The three webs being doffed from the carding machine 63 are indicated at 70, 71, 72 in FIG. 5 and pass through suitable respective condensing means or trumpets of well known type, indicated at 73, 74, 75, from which they emerge as respective slivers 70a, 71a, 72a. The slivers 70a, 71a, 72a then are directed by suitable means, not shown, to the usual feed rolls of the scotch feeder 74 which retains the group of slivers 70a, 71a, 72a in substantially parallel, side by side relationship while conveying them to the sliverlaying means or cross-laying head 80 of the scotch feeder 64.

The cross-laying head 80 may be generally of the type disclosed in U.S. Pat. No. 1,770,239, dated June 8, l930,'but is modified so as to part the slivers 70a,

70b, 70c adjacent each end of its traverse across the feed apron a'of finisher carding machine and thereby form the slivers into independent lengths on apron 65a. Also, head 80 dwells at each end of its traverseso that the previously deposited group of independent lengths of slivers a, 71a, 72a may be advanced toward the feed end of the finisher carding machine 65 and out of the path of the next succeeding group of lengths of sliv ers 70a, 71a, 72a to be deposited upon the finisher card feed apron 65a. Thus, the successive sliver lengths are arranged in substantially parallel, juxtaposed relationship without overlapping at their end portions, so that the lap formed therefrom provides a clearer line of demarcation at the junctures of adjacent sections of different characteristics in the rovings being formed and in the yarns spun therefrom than could be obtainedif the slivers were looped or folded at opposite sides'of feed apron 65a.

Accordingly, cross-laying head includes a traversing carriage 80a (FIGS. 6, 7 and 8) provided with a pair of upper nip rolls 80b anda pair of lower, spaced apart, sliver-guiding idler rolls 80c. Idler rolls 80c are spaced above feed apron 65a sufficiently to accommodate a pusher member or plate 81 therebetween. As shown in FIG. 7, carriage 80a extends rearwardly of apron 65a and is mounted for transverse sliding movementon a pair of stationary guide rods 80d carried by the carding machine frame.

To impart traversing movement to traversing carriage 80a, the lower portion of carriage 80a is provided with a conventional vertically extending guide member 80e which is engaged by a follower 80f mounted on an endless sprocket chain 80g. Chain 80g extends transverselyof the finisher carding machine 65 and is mounted on'a pair of spaced sprocket wheels 80h, 801' suitably journaled on the frame of the carding machine 65. A bevel gear 80j (FIG. 7), which is fixed in axial relation with respect to sprocket wheel 80h, engages a bevel gear 80k fixed on a shaft 80m journaled in one side frame member of carding machine 65 and having a gear 80n fixed on its outer end (FIG. 6).

Gear 80n' meshes with a gear 80p fixed on one end of a shaft 80: journaled in and extending between opposing side frame members of carding machine 65 and having a driven pulley 80r loosely mounted on its other end. Pulley 80r is suitably driven by the usual drive mechanism of the carding machine 65. In order to drive nip rolls 80b during traversing movement of carriage 80a, conventional gear means 80s connects nip rolls 80b to a vertical shaft 801 journaled on carriage 80a and having a pinion 80a on its lower end which engages a rack 80w extending between and secured to the side .frame members of carding machine 65.

Suitable control means is provided for imparting intermittent rotation to shaft 80q to move carriage 80a across the carding machine 65 while permitting carriage 80a to dwell for a predetermined interval of time at the end of each traversing stroke thereof. To this end, an electromagnetic clutch 82 is mounted on shaft 80q' and, when energized, clutch 82 transmits rotation from pulley 80r to shaft 80q to impart traversing movement to carriage 80a through the intervening connections heretofore described. Clutch 82 may be controlled by a suitable electrically operable time delay relay device 82a including a normally closed switch 82b and a normally open switch 82c. Switch 82b is interposed in an electrical circuit to clutch 82, and the coil 82d of time delay device 82a is in series circuit with a pair of normally open stop switches 82e, 82f mounted on the side frame members of the carding machine 65 and positioned adjacent the respective sprocket wheels 80h, 801'.

Thus, each time carriage 80a reaches the end of a traversing stroke thereof, the follower 80f thereon engages and momentarily closes the corresponding switch 82e or 82f, as the case may be, to momentarily energize coil 82d of time delay device 82a and thereby open switch 82b while closing switch 820. The time delay device is arranged so as to maintain the switches 82b,'82c in the latter positions for a predetermined interval of time sufficient for movement of pusher plate 81 from the solid line position of FIG. 7 to the broken line position and back to the solid line position. Since such time delay devices are well known, a further description thereof is deemed unnecessary. After the follower 80f on sprocket chain 80g engages either of the switches 82e or 82f, shaft 80: will coast sufficiently to move follower 80f beyond and out of engagement with the'corresponding switch 82e or 82f, permitting the switch tov open.

As heretofore stated, when coil 82d of time delay device 82a is momentarily energized, switch 820 is moved to closed position, and it should be noted that switch 82c remains in the latter closed position until the delay period of the time delay device 82a has expired. When switch 82c is closed initially, it completes a circuit to a suitable holding relay 81a which then completes a circuit to a solenoid operated valve 81b through a normally closed switch 810 disposed rearwardly of the path of travel of the nip rolls 80b and the idler rolls 800 of cross-laying head 80..

Solenoid valve 81b is normally closed, but is opened upon energization thereof to direct fluid pressure; e.g., compressed air, from a suitable source 81d to the front ends of a pair of fluid-operated cylinders 8le suitably rigidly supported forwardly of and above the level of finisher card feed apron 65a. The front ends of the piston rods of cylinders 8le are suitably secured to opposing end portions of pusher plate 81 so that, upon fluid pressure being introduced to the rear ends of cylinders 8le, pusher plate 81 is moved forwardly to engage and push forwardly the corresponding sliver lengths last laid upon feed apron 65a to position them beyond the plane of the next group of sliver lengths to be deposited on apron 65a. Thereupon, pusher plate 81 engages and opens normally closed switch 810 to deenergize the holding relay 8la-and solenoid valve 81b so that fluid pressure may' escape from cylinders 8le through sole-. noid valve 81b as suitable springs 81f in cylinders 8le return pusher plate 81 to the inactive, solid line position shown in FIG. 7. Thereupon, switches 82b, 82c of timed delay device 820 return to the respective closed and-open positions to impart a succeeding traversing .stroke to carriage 80a.

Any suitable means may be provided for parting the slivers 70a, 71a, 720 as carriage 80a approaches the end of each traversing stroke thereof. By way of example, a cutting device 84 (FIG. 8) is carried by carriage 80a and includes a fixed blade 84a and a movable blade 84b which are pivotally interconnected at 84c and are disposed in the space between the upper and lower pairs of rolls 80b, 800. A spring 84d normally holds blade 84b in inactive or open position with respect to blade 84a.

The outer portion of movable blade 84b is connected to the plunger of a solenoid 842 electrically connected to a'pair of normally open switches 84f, 84g (FIG. 6) arranged in parallel relationship in an electrical circuit to the coil of solenoid 84e. Switches 84f, 843 are positioned adjacent opposite side portions of sprocket chain 80g so as to be engaged and momentarily closed by follower 80f to actuate movable cutter blade 84b and thereby sever the slivers a, 71a, 720 at a predetermined instant before carriage a reaches the end of each traversing stroke thereof. Thereupon, the trailing ends of the corresponding lengths of the slivers 70a, 71a, 72a will drop upon feed apron 650 as carriage 80a reaches the end of the corresponding stroke thereof.

It is thus seen that the cross-laying head 80 serves to successively arrange widthwise of and behind the finisher carding machine independent lengths of textile sliver in substantially parallel, juxtaposed relationship with each of the lengths corresponding substantially to the width of the carding machine and with some of the lengths being of a different color characteristic and/or dye affinity characteristic than others, while feed apron 65a and pusher plate 81 function to feed the thus arranged lengths of textile sliver into the carding machine so that they'areformed into a carded web having successive portions of relatively different characteristics corresponding to the different characteristics of, the

successive independent lengths of the sliv'er fed into the carding machine. Of course, tape condenser 66 func-' tions in the usual manner to split the carded web into a plurality of strips while converting the same into rovings which are wound on the spools 67.

FOURTH EMBODIMENT carding machine.

By way of example, three breaker carding machines 90, 91, 92 are shown in FIG. 9 which form respective carded webs which are, in turn, condensed into respective slivers a, 91a, 92a in the usual manner. The slivers 90a, 91a, 92a issuing from breaker carding machines 90, 91, 92 are of different color and/or dye affinity characteristics relative to each other and are brought together as they are directedto .a common cross-feeding mechanism or scotch feeder 93 which guides the then juxtaposed slivers to the finisher carding machine and cross-lays them onto the feed apron 95a of finisher carding machine 95. Any suitable control means and cutting means may be provided,

such as the apparatus shown in FIGS. 6, 7 and 8, to'

cutting means for the scotch feeder 94 is deemed unnecessary.

Following the positioning of each-successive group of independent lengths of the slivers 90a, 91a, 92a upon and across feed apron 95a (FIG. 9), such group'of lengths may be advanced against the previously advanced group by a suitable pusher member or plate 100 extending over and across feed apron 95a. Pusher plate 100 may be positioned and operated in the same manner as pusher plate 81 (FIGS. 5, 6 and 7).

As heretofore described with respect to the first three embodiments of the invention, the carded web being formed on the finisher carding machine 95 of FIG. 9 passes into a condenser 96 which splits the carded web into a plurality of strips, which are in turn, converted into yarn rovings and wound on the spools 97.

As is conventional, textile fibers from separate sources, not shown, are fed into the breaker carding machines 90, 91, 92. However, the fibers being fed to breaker carding machines 90, 91, 92 are of respectively different color characteristics and/or dye afiinity characteristics so that each sliver 90a, 91a, 92a emerging from the respective breaker carding machines 90, 91, 92 is of a different color and/or affinity from that of the other slivers being directed to the scotch feeder 93. In this regard, suitable driven conveyors or aprons 90b,

92b may be provided for advancing the slivers 90a, 92a

emerging from the respective breaker carding machines 90, 92 to the scotch feeder 93 to combine them with and position them in parallel relation to the sliver 91a emerging from carding machine 91 and so that all three of the slivers 90a, 91a, 92a are arranged and then maintained in substantially parallel side by side relationship.

In order to vary the successive arrangement of the fibers of different characteristics, the production of the breaker carding machines 9092 may be interrupted in the desired sequence, either by an operator or by a suitable control means, not shown, provided that at least one or another of the breaker carding machines is operating during operation of the finisher carding machine 95. The strokes of pusher plate 100 (FIG. 9) may be suitably varied in accordance with variation in the number of slivers being guided to the cross-laying head of the scotch feeder 93 so that the lap being formed is of substantially uniform density throughout its length.

In other respects, the machinery shown in FIG. 9 may operate in the same manner as that described with respect to themachinery shown in FIGS. 5, 6, 7 and 8 and, therefore, a further description thereof is deemed unnecessary.

FIFTH EMBODIMENT The fifth embodiment of the invention shown in FIGS. l0, l1 and 12 also includes means for successively arranging individual lengths of textile slivers on the feed apron 105a of, and widthwise of, a finisher carding machine 105 to form a carded web from the lap formed of the successive independent lengths of textile sliver. Such carded web is split into a plurality of tapes as it passes from carding machine 105 through a condenser 106 which converts the strips being formed into yarn rovings which are wound on spools 107. The fifth embodimentof the invention differs from the first four embodiments heretofore described in that, instead of the slivers of relatively different color and/or dye affinity characteristics being fed to the finisher carding machine directly from a breaker carding machine or plurality' of breaker carding machines, the slivers are drawnfrom independent sources; e.g., supply packages, containers or sliver cans, and deposited on the feed apron 105a of the finisher carding machine 105.

As shown, by way of example, four slivers 111, 1 12, 113, 114 are taken from respective sources embodied in respective sliver cans 111a, 112a, 113a, 114a. The slivers 111, 112, 113, 114 may be formed into the packages represented by sliver cans-111a, 112a, 113a, 114a, by carding machines, draw frames, gilling machines, combining machines or any other sliver forming machines, as desired. As preferred, it is to be assumed that each of the slivers 111-114 is formed of fibers of a different color and/or dye affinity than the fibers of the other slivers. However, it is to be understood that two or more, but less than all of the slivers 111-114 may be of the same color or dye affinity without departing from the invention.

Suitable means is provided for selectively drawing the slivers 111-114 from the respective cans 11 la-1l4a and depositing independent legnths thereof in substantially parallel, juxtaposed relationship on feed apron 105a'of finisher carding machine 105 so that each of the sliver lengths corresponds substantially to the width of the carding machine. By way of example, with the sliver cans 1 1 1a-114a positioned adjacent one sideof carding machine as shown in FIG. 10, each sliver may be successively drawn from its corresponding sliver can, severed into the desired lengths and deposited on feed apron 105a by means of the apparatus shown in FIGS. 11 and 12 associated with sliver can 114a.

It will be observed that sliver '1 14 is drawn from can 114a by a pair oflifter rolls and a succeeding pair of feed rolls 121. Feed rolls 121 are positioned closely adjacent one side of, and above the level of, feed apron 105a and are driven in timed relation with a suitable traversing sliver-laying head 125 supported, on a stationery guide bar 126, for reciprocatory movement above and across feed apron 105a.

Each sliver-laying head 125 includes a pair of normally open, relatively movable grippers 1250 connected, as by toggle linkage 125b, to an actuator 1250. As each respective head 125 approachesthe end of an inactive stroke thereof toward the respective pair of feed rolls 121; from left to right in FIG. 11, actuator 125C engages a stationery abutment 127 which moves actuator 125C relative to the housing of head 125 to thereby close grippers 125a to grip the leading end of the respective sliver therebetween.

An active stroke then is imparted to the respective head 125, whereupon grippers 125a move into engagement with a releasing member 130 (FIG. 1 1) carried by the carding machine frame so as to open the grippers and permit the corresponding end of the sliver to drop onto feed apron 105a. As grippers 125a open, a suitable cutting means 131 positioned above apron 105a and inwardly of feed rolls 121 (FIG. 12), severs the corresponding sliver so that a length thereof is'deposited on apron 105a.

Each cutting means 131 may be operated by a solenoid 132, suitably connected to a movable blade of the cutting means 131 and controlled by a normally inactive switch 133 in an electrical circuit to solenoid 132. Switches 133 are carried bythe carding machine frame and are positioned remote from the cutting means 131 17 so that each switch 133 is engaged and activated momentarily by the respective sliver-laying head 125 as it reaches the end of each active stroke thereof.

Switches 133 also may be electrically connected to a suitable electrically operable motive means 134 for driving a pusher plate 135 (FIG. Pusher plate 135 extends across and above feed apron 105a and normally is positioned rearwardly of the path of travel of the sliver-laying heads 125. Upon energization of motive means 134, it imparts a reciprocation to pusher plate 135 to push forwardly the lengths of sliver, previously deposited on apron 1050 by a head or heads 125, against the rearmost of the preceding sliver lengths forming the lap L being fed into the finisher carding machine 105. Any suitable means, not shown, may be provided for controlling the length of each active or forward stroke of pusher plate 135 in accordance with the number of lengths of sliver to be advanced to the lap L. It is apparent that pusher plate 135 then returns to the normal or inactive position shown in FIG. 10 and remains in such position until a succeeding reciprocatory traversing movement has been imparted to one or more of the sliver-laying heads 125. 1

Any suitable means may be provided for selectively imparting traversing movement to sliver-laying heads 125 according to a predetermined pattern and fordriving the corresponding lifter rolls 120 and feed rolls 121. By way of example, each sliver-laying head 125 may be attached to'a respective cable 140 extending above and parallel with the corresponding guide bar 126. At op posite sides of the carding machine 105, cable 140 extends partially around a pair of pulleys 141, 142 suitably journaled on the frame of the carding machine, and the upper reach of each cable 140 loosely penetrates the otherwise closed opposite ends of a stationery cylinder 143 and is connected to a piston 144 positioned within cylinder 143. Conduits 145 connect opposite ends of cylinders 143 to a bank of selector valves 147 shown schematically in the upper portion of FIG. 10.

Selector valves 147 are connected to a suitable source of fluid pressure 150 and are controlled by suitable electrical controls 151 operated by a suitable pattern device 152. Since pattern controlled valves are well known, a detailed illustration and description of valves 147, electrical controls 151 and pattern device 152 is deemed unnecessary. It is apparent that, upon fluid pressure being introduced into the right-hand end of cylinder 143 in FIG. 11, an inactive stroke is imparted to the corresponding Sliver-laying head 125 and, upon fluid pressure being introduced into the left-hand end of cylinder 143, an active stroke is imparted to the corresponding sliver-laying head 125 to return the same to the position of rest in FIG. 11.

A'suitable one-way clutch 155, disposed in fixed axial relation with respect to pulley 142, is engaged .by an endless belt 156 which also engages a pulley 157 disposed in fixed axial relation to top feed roll 121. A suitable belt and pulley connection 160 may also be provided between top feed roll 121 and top lifter roll 120 as shown in FIG. 11. One-way clutch 155 may be of well-known form and is so arranged that, during each inactive stroke of the corresponding sliver-laying head 125 from left to right in FIG. 1 I, pulley 142 will rotate independently of lifter rolls 120 and feed rolls 121. However, upon each active stroke of a respective sliver-laying head 125, from right to left in FIG. 11, oneheretofore described.

way clutch 155 will transmit rotation from pulley 142,, to lifter rolls and feed rolls 121 to thereby draw the sliver from the corresponding sliver can as the sliver is drawn across and above the feed apron 105a by the corresponding sliver-laying head in the manner When the respective slivers 111ll4 are severed by the corresponding cutting means 131, it is apparent that the cutting devices 131 will be positioned in alignment with the then leading end of the slivers extending from the sliver cans 111a-114a. Therefore, in order to expose the leading end of each sliver for being engaged by the grippers 125a of each respective sliver-laying head 125, each cutting device 131 may be yieldably supported so that a roller or abutment on the lower jaw of the grippers 125a' may engage and push the corresponding cutting device 131 toward feed rolls 121 as the respective sliver-laying head 125 reaches the end of an inactive stroke thereof and so that a short length of the sliver then is'protruding inwardly beyond the cutting device 131 to be engaged by the grippers 125a in the manner heretofore described.

,To this end, the supporting frame of each cutting device 131 is mounted for inward and outward movement on a stationery guide member 163 and engages a suitable compression spring 164 which bears against the frame of the carding machine. Thus, upon an active stroke being imparted to each respective sliver-laying head 125, the corresponding cutting means 131 returns to its normal position before the corresponding sliverlaying head 125 reaches the end of its active stroke and, thus, before the corresponding cutting device 131 is activated to sever the corresponding sliver.

From the foregoing description, it is thus seen that lengths of the slivers 111-114 may be selectively drawn from sliver cans Illa-114a and deposited in any desired order on feed apron 105a in the interim between successive reciprocations of pusher plate 135, so that respective independent lengths of slivers of relatively different colors and/or dye affinities may be fed to and formed into the lap L in any desired sequence. Thus, carding machine 105 will form the sliver lengths into a carded web having successive portions of relatively short lengths which are of different relative color and- /or dye affinity characteristics, without the fibers of one color or dye affinity being intermixed to any noticeable degree with the fibers of another color or dye affinity, to provide a clear line of demarcation between immediately successive portions of the carded web having such different color and/or dye affinity characteristics. This will result in a roving and a consequent yarn being formed therefrom which has relatively short-length successive portions of relatively different characteristics with a clear line of demarcation at the junctures thereof, and thereby result in a yarn having the appearance of a conventionally space-dyed yarn.

In the drawing and specification, there have been set forth preferred embodiments of the invention, and although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation.

That which is claimed is:

1. In a method of making space-dyed yarns utilizing textile fibers of different color characteristics and/or dye affinity characteristics, the steps of successively forming elongate rows of masses of textile fibers with each row having at least two longitudinal fibrous sections which differ from each other as to said characteristics,

arranging in side by side relationship a predetermined number of the rows of fibers with like fibrous sections thereof arranged beside each other in side by side relationship,

directing the predetermined number of side by side arranged rows of fibers longitudinally of the respective rows into and through a first carding machine to form a carded web having successive portions of different characteristics corresponding to the different characteristics of the respective sections of the rows of fibers,

condensing the web into a sliver as it emerges from the first carding machine,

cross-laying the sliver onto the feed apron of a second carding machine,

directing the cross-laid sliver into and through the second carding machine to again form a carded web from the sliver,

splitting the last-named web into a plurality of relatively narrow strips, and

converting the strips into yarn rovings.

2. In a method of making space-dyed yarns utilizing textile fibers of different color characteristics and/or dye affinity characteristics, the steps of successively forming elongate rows of masses of textile fibers with each row having at least two longitudinal fibrous sections which differ from each other as to said characteristics, arranging in side by side relationship a predetermined number of the rows of fibers with like fibrous sections thereof arranged beside each other in side by side relationship, directing the predetermined number of side by side arranged rows of fibers longitudinally of the respective rows into and through a carding machine to form a carded web having successive portions of different characteristics corresponding to the different characteristics of the respective sections of the rows of fibers,

processing the web through another carding machine and thereafter converting the same into yarn rovings, and

wherein the arranging of the elongate rows of masses of textile fibers in side by side relationship comprises moving the successive rows being formed from a position to one side of the first mentioned carding machine to a position in back of and in alignment with the first mentioned carding machine while positioning adjacent rows of fibers in substantially abutting relationship until said predetermined number of rows are accumulated in back of the first mentioned carding machine.

3. In a method of making space-dyed yarns utilizing textile fibers of different color characteristics and/or dye affinity characteristics, the steps of successively forming elongate rows of masses of textile fibers with each row having at least two longitudinal fibrous sections which differ from each other as to said characteristics,

arranging in side by side relationship a predetermined number of the rows of fibers with like fibrous sections thereof arranged beside each other in side by side relationship,

directing the predetermined number of side by side arranged rows of fibers longitudinally of the respective rows into and through a first carding machine to form a carded web having successive portions of different characteristics corresponding to the different characteristics of the respective sections of the rows of fibers, and

processing the web through another carding machine and thereafter converting the same into yarn rovings while repeating-the step of forming the rows of fibers and the step of arranging a predetermined number of the rows, and directing each succeeding predetermined number of rows thus formed longitudinally of the respective rows into substantially abutting relation to the respective preceding predetermined number of rows.

4. In a method of making space-dyed yarns utilizing textile fibers of different color characteristics and/or dye affinity characteristics; the steps of guiding the thus arranged group of slivers back and forth upon and across the feed apron of a carding machine,

forming the group of slivers into independent juxtaposed lengths corresponding substantially to the width of the carding machine by parting the slivers adjacent the corresponding side of the feed apron each time a length of the group of slivers is guided across the feed apron, while feeding the successive independent lengths on the feed apron into the carding machine, carding the successive lengths through the carding machine to'form a carded web having successive portions of different characteristics corresponding to the different characteristics of the respective lengths of the slivers, splitting the web into strips, converting the strips into yarn rovings, and wherein thestep of forming and arranging said group of slivers includes feeding at least two side by side masses of textile fibers which differ from each other as to said characteristics into a breaker carding machine, while carding the masses in segregated relationship through the breaker carding machine to form separate side by side carded webs from the respective segregated masses, condensing the webs issuing from the breaker carding machine into respective slivers while bringing the slivers into juxtaposed non-overlapping relationship, and while conveying the slivers from the breaker carding machine to the first-named carding machine. 5. In an apparatus for forming yarn rovings for the making of spaced-dyed yarns therefrom and utilizing textile fibers of different color characteristics and/or dye affinity characteristics, said apparatus including a carding machine having a driven feed apron; the combination there with of means for successively laying groups'of at least two textile slivers, which differ from each other as to said characteristics, in substantially parallel, juxtaposed relationship upon and across said feed apron of said carding machine, means for forming and directing said groups of textile slivers to said laying means and comprising a breaker carding machine, means for feeding at least two side by side masses of textile fibers which differ from each other as to said characteristics into said breaker carding machine, segregating means maintaining said masses of textile fibers in segregated relationship throughout the forming of respective, separate, side by side carded webs therefrom through the breaker carding machine, means condensing the webs issuing from the breaker carding machine into respective slivers to form a group thereof, means for bringing the slivers issuing from the breaker carding machine into juxtaposed relationship, means for conveying the juxtaposed slivers to said laying means, said laying means including means for guiding the group of slivers being conveyed thereto back and forth upon and across the feed apron of said firstnamed carding machine, means operatively associated with said laying means for par'tingthe slivers adjacent the corresponding side of the feed apron each time the group of slivers is laid across the feed apron to form the slivers into respective independent lengths corresponding substantially to the width of said feed apron whereby the feed apron successively feeds the independent lengths thereon into the first-named carding machine which forms a carded web from said lengths which web has successive portions of different characteristics corresponding to the different characteristics of the respective independent lengths of slivers, and means on the front end of the first-named carding machine for splitting the web thus formed into strips and converting the strips into the yarn rovings.

1 TED STATES PATENT oTTTcE @E'HHCATE GE QQEUHGN Patent No, 3, 815, 179 Dated June 11, 1974 Inventm-(S) James Melvin Moore, et al It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:

Column 2, Line 1, change "fed" to --feed-.

Column 6, Line 57, after "Transfer" insert -platform- Column 12, Line 25, after "extends" insert -downwardly- Column 16, Line 22, change "legnths" to -lengths igned and salad this twenty-seventh ay 0? April1976 [SEAL] Arrest:

RUTH C. MASON C. MARSHALL DANN Arresting Office (ummissimwr oj'Purents and Trademarkx 

1. In a method of making space-dyed yarns utilizing textile fibers of different color characteristics and/or dye affinity characteristics, the steps of successively forming elongate rows of masses of textile fibers with each row having at least two longitudinal fibrous sections which differ from each other as to said characteristics, arranging in side by side relationship a predetermined number of the rows of fibers with like fibrous sections thereof arranged beside each other in side by side relationship, directing the predetermined number of side by side arranged rows of fibers longitudinally of the respective rows into and through a first carding machine to form a carded web having successive portions of different characteristics corresponding to the different characteristics of the respective sections of the rows of fibers, condensing the web into a sliver as it emerges from the first carding machine, cross-laying the sliver onto the feed apron of a second carding machine, directing the cross-laid sliver into and through the second carding machine to again form a carded web from the sliver, splitting the last-named web into a plurality of relatively narrow strips, and converting the strips into yarn rovings.
 2. In a method of making space-dyed yarns utilizing textile fibers of different color characteristics and/or dye affinity characteristics, the steps of successively forming elongate rows of masses of textile fibers with each row having at least two longitudinal fibrous sections which differ from each other as to said characteristics, arranging in side by side relationship a predetermined number of the rows of fibers with like fibrous sections thereof arranged beside each other in side by side relationship, directing the predetermined number of side by side arranged rows of fibers longitudinally of the respective rows into and through a carding machine to form a carded web having successive portions of different characteristics corresponding to the different characteristics of the respective sections of the rows of fibers, processing the web through another carding machine and thereafter converting the same into yarn rovings, and wherein the arranging of thE elongate rows of masses of textile fibers in side by side relationship comprises moving the successive rows being formed from a position to one side of the first mentioned carding machine to a position in back of and in alignment with the first mentioned carding machine while positioning adjacent rows of fibers in substantially abutting relationship until said predetermined number of rows are accumulated in back of the first mentioned carding machine.
 3. In a method of making space-dyed yarns utilizing textile fibers of different color characteristics and/or dye affinity characteristics, the steps of successively forming elongate rows of masses of textile fibers with each row having at least two longitudinal fibrous sections which differ from each other as to said characteristics, arranging in side by side relationship a predetermined number of the rows of fibers with like fibrous sections thereof arranged beside each other in side by side relationship, directing the predetermined number of side by side arranged rows of fibers longitudinally of the respective rows into and through a first carding machine to form a carded web having successive portions of different characteristics corresponding to the different characteristics of the respective sections of the rows of fibers, and processing the web through another carding machine and thereafter converting the same into yarn rovings while repeating the step of forming the rows of fibers and the step of arranging a predetermined number of the rows, and directing each succeeding predetermined number of rows thus formed longitudinally of the respective rows into substantially abutting relation to the respective preceding predetermined number of rows.
 4. In a method of making space-dyed yarns utilizing textile fibers of different color characteristics and/or dye affinity characteristics; the steps of forming and arranging a group of at least two textile slivers in juxtaposed relationship with the slivers differing from each other as to said characteristics, guiding the thus arranged group of slivers back and forth upon and across the feed apron of a carding machine, forming the group of slivers into independent juxtaposed lengths corresponding substantially to the width of the carding machine by parting the slivers adjacent the corresponding side of the feed apron each time a length of the group of slivers is guided across the feed apron, while feeding the successive independent lengths on the feed apron into the carding machine, carding the successive lengths through the carding machine to form a carded web having successive portions of different characteristics corresponding to the different characteristics of the respective lengths of the slivers, splitting the web into strips, converting the strips into yarn rovings, and wherein the step of forming and arranging said group of slivers includes feeding at least two side by side masses of textile fibers which differ from each other as to said characteristics into a breaker carding machine, while carding the masses in segregated relationship through the breaker carding machine to form separate side by side carded webs from the respective segregated masses, condensing the webs issuing from the breaker carding machine into respective slivers while bringing the slivers into juxtaposed non-overlapping relationship, and while conveying the slivers from the breaker carding machine to the first-named carding machine.
 5. In an apparatus for forming yarn rovings for the making of spaced-dyed yarns therefrom and utilizing textile fibers of different color characteristics and/or dye affinity characteristics, said apparatus including a carding machine having a driven feed apron; the combination there with of means for successively laying groups of at least two textile slivers, which differ from each other as to said characteristics, in substantially parallel, juxtaposed relationship upon and across said feed apron of said Carding machine, means for forming and directing said groups of textile slivers to said laying means and comprising a breaker carding machine, means for feeding at least two side by side masses of textile fibers which differ from each other as to said characteristics into said breaker carding machine, segregating means maintaining said masses of textile fibers in segregated relationship throughout the forming of respective, separate, side by side carded webs therefrom through the breaker carding machine, means condensing the webs issuing from the breaker carding machine into respective slivers to form a group thereof, means for bringing the slivers issuing from the breaker carding machine into juxtaposed relationship, means for conveying the juxtaposed slivers to said laying means, said laying means including means for guiding the group of slivers being conveyed thereto back and forth upon and across the feed apron of said first-named carding machine, means operatively associated with said laying means for parting the slivers adjacent the corresponding side of the feed apron each time the group of slivers is laid across the feed apron to form the slivers into respective independent lengths corresponding substantially to the width of said feed apron whereby the feed apron successively feeds the independent lengths thereon into the first-named carding machine which forms a carded web from said lengths which web has successive portions of different characteristics corresponding to the different characteristics of the respective independent lengths of slivers, and means on the front end of the first-named carding machine for splitting the web thus formed into strips and converting the strips into the yarn rovings. 